Repair Procedures

Inspection Of The Secondary Air Filter Case, Air Hose.

Air Filter Case:

1. Inspect the Secondary Air Filter Case and Air Hose for signs of melting. In the rare case of melting, replace:

- Reed Valve Subassembly
- A.C.V. Assembly
- Air Hose
- Secondary Air Filter Case

2. If there is no visible damage to either the Secondary Air Filter Case or Air Hose, proceed to, AIR CONTROL VALVE ASSEMBLY (A.C.V.) IDENTIFICATION

AIR CONTROL VALVE ASSEMBLY (A.C.V.) IDENTIFICATION Two types of A.C.V.s were used In 1986-1989 Model Year Hyundai Excel emissions control systems.

Air Control Valve:

2 VACUUM LINE TYPE

- Federal Spec. vehicles with:
^ Automatic transaxle up to 05/17/1987 production
^ Manual transaxle up to 06/02/1987 production

Air Control Valve:

1 VACUUM LINE TYPE

- All California Spec. vehicles
- Federal Spec. vehicles with:
^ Automatic transaxle after 05/17/1987 production
^ Manual transaxle after 06/03/1987 production

DISASSEMBLY OF THE A.C.V. ASSEMBLY

Air Control Valve:

1. Disconnect the air hose and the vacuum line/lines. (On the vehicles with 2 vacuum lines, mark the lines to insure proper reinstallation)

Air Control Valve:

2. Remove the 4 mounting screws from the inlet body. If necessary, use pliers or visegrips to loosen screws. Discard the old screws since new ones are supplied with the new reed valve subassembly.

NOTE:
Do not remove the A.C.V. outlet body from the air pipe.

Air Control Valve:

3. Remove the inlet body and the reed valve subassembly. Be careful not to drop the "0"-ring and A.C.V. seatplate used only on the 2 vacuum line type.

Reed Valve Subassembly:

4. Inspect the inside of the large air inlet nipple for the presence of carbon deposits, and the inside of the inlet body for the condition of the rubber air stopper.

Air Control Valve:

a) If there are carbon deposits inside the air inlet nipple, or the rubber air stopper is damaged, replace both the A.O.V. assembly and reed valve subassembly with new parts.

b) If there is no carbon present inside the air inlet nipple, and the rubber stopper is undamaged replace only the reed valve subassembly with a new part. The same A.C.V assembly may be reinstalled.

NOTE:
DO NOT DISASSEMBLE THE A.C.V. OUTLET BODY FROM THE AIR PIPE.

Installation Procedure

Air Control Valve:

2 Vacuum Line Type A.C.V.

Air Control Valve:

1 Vacuum Line Type A.C.V.

Reed Valve Subassembly:

1. Install the reed valve subassembly into the air control valve outlet body as illustrated.

NOTE:

Reed Valve Position:

Be sure that the reed valves open toward the air pipe. This Installation Is the same on both type A.C.V.s.

Air Control Valve:

2. Assemble the inlet body as shown. (2 vacuum line type)

NOTE:
Make sure that the "O"-ring is seated properly In the Inlet body.

Air Control Valve:

2a. Assemble the inlet body as illustrated. (1 vacuum line type)

Air Control Valve:

3. Install the inlet body to the outlet body using the new screws supplied with the reed valve subassembly, and tighten the mounting screws in the sequence as shown in the illustration.

* Tightening torque: 2.2 ft.lb3Okg.cm

4. Connect the air hose and vacuum lines.

Engine I.D Plate:

5. After the air hoses and vacuum lines have been reconnected, place a punch mark over the first letter on the engine compartment identification plate as illustrated. This will indicate that the campaign procedures have been completed.
6. Start engine and quality check job.